Recyclable container adapted for movement by a lifting device and method for making same

ABSTRACT

A container for storing material, such as welding wire. The container is adapted to be lifted by inserting a fork, or other lifting member, of a lifting device into the container. The container may comprise a fiber drum having one or more openings, or recesses, adapted to receive a fork of a lifting device. The container may be cylindrical. The container may be comprised of a cellulosic material. The container may house welding wire. A method of manufacturing a container adapted to be lifted by inserting a member of a lifting device into the container also is featured.

BACKGROUND OF THE INVENTION

[0001] The present invention relates generally to the field ofcontainers, and more particularly to a recyclable container that isadapted for movement by a forklift, and that may be used to storewelding wire and other materials.

[0002] Recyclable containers, such as fiber drums are used to store avariety of products and materials. For example, fiber drums may be usedto store wire for use in an arc welding system. In some arc weldingsystems, such as MIG (Metal Inert Gas) welding systems, metal wire isused as an electrode to produce an arc. The welding wire also acts asfiller material and is consumed during the welding process. Typically,the welding wire is fed from a wire feeder to a hand-held welding gun. Awelding wire supplier may provide the welding wire to a customer in afiber drum. A typical fiber drum used for storing welding wire is hollowand formed of a cellulosic material, such as paper or cardboard. Inaddition, a typical fiber drum has a metal band around the top to enablethe fiber drum to be lifted by a device coupled to the metal band. Inaddition, special straps may be needed to move the fiber drum onto apallet or to remove the fiber drum from the pallet. The weight of thefiber drums may make movement of the fiber drums difficult. Thus, thefiber drum is placed on a pallet when being moved. A forklift, or otherlifting device may then move the pallet.

[0003] Fiber drums typically are discarded after the wire, or othermaterial housed therein, is consumed because the fiber drums cannoteasily be recycled. Recycling is difficult because the cellulosicportion of the drum must be separated from the metal portion of the drumto recycle either the fibrous portion or the metal portion. Thatoperation can be complex and time consuming. Thus, a typical fiber drumowner ultimately pays to dispose of the empty fiber drum as refuse,rather than regaining some of the cost of the fiber drum by recycling.

[0004] Therefore, a need exists for a fiber drum that may be used totransport heavy materials, such as welding wire, and that is easier tomove than conventional fiber drums. In addition, a need exists for afiber drum that is recyclable, or that can be made recyclable withminimal time and effort.

SUMMARY OF THE INVENTION

[0005] The present invention provides a technique designed to respond tosome or all of these needs. According to one aspect of the presenttechnique, an apparatus for storing materials, such as welding wire, isfeatured. The container may be adapted to be lifted by inserting aportion of a lifting device into a hole or recess in the container. Thecontainer may comprise a fiber drum having one or more openings adaptedto receive a fork of a lifting device. The container may be cylindricaland have a false bottom to support the welding wire. The container maybe comprised of a cellulosic material. The container may house weldingwire.

[0006] According to another aspect of the present technique, a method ofmanufacturing a container adapted to be lifted by inserting a member ofa lifting device into the container is featured. The method may compriseadapting a cylindrical fiber drum with an opening operable to receive atleast one member of a lifting device. The method also may comprisedisposing a false bottom into the container to support the contents,such as welding wire, above the opening in the fiber drum.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] The foregoing and other advantages and features of the inventionwill become apparent upon reading the following detailed description andupon reference to the drawings in which:

[0008]FIG. 1 is a diagrammatical view of a wire welding system,according to an exemplary embodiment of the present technique;

[0009]FIG. 2 is an elevational view illustrating the lifting of a fiberdrum by a forklift, according to an exemplary embodiment of the presenttechnique;

[0010]FIG. 3 is a cross-sectional view of the fiber drum of FIG. 1,taken generally along line 3-3 of FIG. 1;

[0011]FIG. 4 is an elevational view of a false bottom for a fiber drum,according to an exemplary embodiment of the present technique;

[0012]FIG. 5 is a top view of the false bottom of FIG. 4, according toan exemplary embodiment of the present technique;

[0013]FIG. 6 is a top view of an alternative embodiment of a fiber drum,according to an exemplary embodiment of the present technique;

[0014]FIG. 7 is a top view of a second alternative embodiment of a fiberdrum, according to an exemplary embodiment of the present technique;

[0015]FIG. 8 is a top view of the fiber drum of FIG. 7 and analternative embodiment of a false bottom, illustrating the insertion offorks into the fiber drum from a first direction, according to anexemplary embodiment of the present technique; and

[0016]FIG. 9 is a top view of the fiber drum of FIG. 7 and analternative embodiment of a false bottom, illustrating the insertion offorks into the fiber drum from a second direction, according to anexemplary embodiment of the present technique.

DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS

[0017] Referring generally to FIG. 1, a wire-welding system 10, such asa MIG welding system, is featured. In the illustrated embodiment,wire-welding system 10 comprises a wire feeder 12, a power source 14, agas cylinder 16 and a recyclable container 18 containing welding wire20. Preferably, the recyclable container 18 is comprised of a fibrousmaterial, such as cellulosic paper, paperboard, or cardboard.

[0018] The power source 14 provides electricity to the wire feeder 12;the gas cylinder 16 provides inert gas to the wire feeder 12; and thecontainer 18 provides welding wire 20 to the wire feeder 12. In theillustrated embodiment, the wire feeder 12 provides electricity, weldingwire 20, and inert gas to a welding torch 22. The wire, gas, andelectricity are coupled to the torch 22 by a welding cable 24. Inaddition, a work clamp 26 is coupled to the wire feeder 12 by a groundcable 28. The work clamp 26 is secured to a workpiece 30 to electricallycouple the workpiece 30 to the wire feeder 12. The torch 22 controls theoperation of the system 10. When the torch 22 is activated, welding wire20 is fed through the torch 22 by the wire feeder 12. When the weldingwire 20 contacts the workpiece 30, an electrical circuit between theworkpiece 30 and the wirefeeder 12 is completed and an electric arc isproduced. The electric arc melts the workpiece 30 and welding wire 20 atthe point of contact. The inert gas shields the molten area fromcontaminants. A power cable 32 conducts electricity from the powersource 14 to the wire feeder 12. A hose 34 channels gas from the gascylinder 16 to the wire feeder 12. A conical adapter 36 feeds thewelding wire from the container 18 to the wire feeder 12.

[0019] In the illustrated embodiment, the container 18 is a hollow,generally cylindrical fiber drum and the adapter 36 has a conformingcircular bottom adapted to fit atop the fiber drum cylinder. However,the container 18 may have a shape other than a cylindrical shape. Forexample, the container 18 may be square, hexagonal, octagonal, etc. Aspool of welding wire is disposed within the hollow interior of thefiber drum 18. The welding wire 20 is unwound from the spool and fedfrom the fiber drum 18 through a hole (not shown) in the adapter 36.Additional means may be used to direct the welding wire 20 to the wirefeeder 12.

[0020] In the illustrated embodiment, the fiber drum 18 has at leastone, and as illustrated, a plurality of holes, or recesses, 40 locatedon a bottom portion of the fiber drum 18. As best illustrated in FIG. 2,the fiber drum 18 is adapted to enable the forks 42 of a forklift 44, orother member of a lifting device, to enter one or more of the pluralityof holes, or recesses, 40 and be positioned below the welding wire 20 tolift the fiber drum 18. In the illustrated embodiment, two holes 40 areused, one for each fork 42 of the forklift 44. However, the fiber drum18 also may be adapted with a single hole, or recess, that enables twoforks 42, or a single lifting member to enter the fiber drum 18. Inaddition, exit holes may be provided to enable the forks 42 to extendthrough the fiber drum 18. Furthermore, a lifting device other than aforklift 44 may be used to lift the fiber drum 18 via one or more of theholes 40, or other (i.e. open) recesses. For example, lifting strapscould be passed through the openings to enable an overhead crane to liftthe container 18. Other lifting devices may also be used.

[0021] Referring generally to FIG. 3, an exemplary embodiment of a fiberdrum 18 is illustrated. In the illustrated embodiment, the fiber drum 18has a cylindrical portion 46, a bottom 48, a lid 50, and a false bottom52. The false bottom 52 is placed within the cylindrical portion 46 andthe welding wire 20 is then placed atop the false bottom 52. A removablemetal ring 54 is placed above the welding wire 20 to secure the weldingwire 20 during shipping. In this embodiment, an elastic strap 56 andmetal rod 58 are used to drive the metal ring 54 downward to secure thewelding wire 20 within the cylindrical housing 46 during transport. Thering 54 and rod 58 may be removed from the fiber drum 18 when the drumis placed in service. The elastic strap 56 also may be removed at thistime. In the illustrated embodiment, the cylindrical portion 46, bottom48, lid 50, and false bottom 52 are composed of a fibrous material, suchas cellulosic paper, paperboard, or cardboard. However, the lid 50 mayhave a metal band to secure the lid 50 to the cylindrical portion 46during transport. In this embodiment, the cylindrical housing 46, bottom48, and false bottom 52 are adapted to be free of metal so that they maybe more readily recycled once the welding wire has been consumed. Themetal ring 54 and metal rod 58 may be recycled as metal once they areremoved from the fiber drum 18.

[0022] Referring generally to FIGS. 4 and 5, a plurality of supports 60are secured to the false bottom 52. The plurality of supports 60 andfalse bottom 52 are adapted to support the welding wire 20 above thebottom to provide clearance for the forks 42 of the forklift 44 to enterthe fiber drum 18 below the wire 20. In the illustrated embodiment, thesupports 60 also are adapted from cellulosic cylinders, such ascardboard tubing. However, the supports 60 may be comprised of anothersuitable material. In this embodiment, there are circular supports 62and semi-circular supports 64. The semicircular supports 64 may beadapted from the circular supports 62, for example, by cutting them inhalf lengthwise. Preferably, the supports 60 are secured, such as byglue, to the bottom 48 and the false bottom 52. The false bottom 52 alsomay be secured to the cylindrical portion 46 of the fiber drum 18.Furthermore, rather than using a false bottom 52 and the plurality ofholes 40, the fiber drum 18 may be adapted with the supports 60 securedto the bottom 48 of the fiber drum 18 from below, rather than fromabove, to create a space for the forks 42, or another lifting member, tobe positioned below the bottom 48 of the fiber drum 18.

[0023] In the illustrated embodiment, the false bottom 52 has a hole 66to enable the elastic strap 56 to pass through the false bottom 52.Furthermore, the cylindrical housing 46, bottom 48, false bottom 52, andsupports 60 are adapted to be free of metal so that they may be morereadily recycled as a fibrous material once the welding wire has beenconsumed. The metal ring 54 and metal rod 58 may be recycled as metalonce they are removed from the fiber drum 18.

[0024] Referring generally to FIG. 6, an alternative embodiment of afiber drum 68 is illustrated. In the embodiment illustrated, a secondplurality of holes 40 are provided opposite the first plurality of holes40 to enable the forks to extend through the fiber drum 18 and to enablethe forks to enter the fiber drum from a second orientation.

[0025] Referring generally to FIG. 7, a second alternative embodiment ofa fiber drum 70 is illustrated. In the illustrated embodiment, there arefour pairs of holes disposed in fiber drum 70, one pair in eachquadrant. The plurality of holes 40 enable the forks 42 to enter thefiber drum 70 from four directions.

[0026] Referring generally to FIGS. 8 and 9, an alternative embodimentof a false bottom 72 disposed within the fiber drum 70 is featured. Thefalse bottom 72 is adapted to be aligned with the plurality of holes 40to provide clearance for the forks 42 to enter the fiber drum 70 fromeach of four directions around the fiber drum 70.

[0027] The illustrated embodiments of fiber drums described above enablethe metal portions of the fiber drums to be easily separated from thenon-metal portions of the fiber drums, thus enabling the fiber drums tobe recycled easily. In addition, the fiber drums described above areeasily moved by standard lifting devices, such as forklifts, without theneed of special lifting straps or pallets.

[0028] While the invention may be susceptible to various modificationsand alternative forms, specific embodiments have been shown by way ofexample in the drawings and have been described in detail herein.However, it should be understood that the invention is not intended tobe limited to the particular forms disclosed. Rather, the invention isto cover all modifications, equivalents, and alternatives falling withinthe spirit and scope of the invention as defined by the followingappended claims. For example, the holes in the cylindrical portion andthe supports may be arranged in a myriad of orientations to enable thefiber drum to be lifted from a number of different orientations. Inaddition, the holes in the cylindrical portion of the container may beadapted to receive a lifting member other than the forks of a forklift.

What is claimed is:
 1. A container, comprising: a housing comprising acellulosic material, the housing being adapted to receive at least onelifting member of a lifting device into one of an opening and a recessin the housing.
 2. The container as recited in claim 1, wherein thehousing is cylindrical.
 3. The container as recited in claim 1, furthercomprising a bottom and a support surface adapted to support a materialwithin the housing.
 4. The container as recited in claim 3, wherein thehousing comprises at least one opening adapted to enable the at leastone lifting member to enter the housing between the bottom and thesupport surface.
 5. The container as recited in claim 4, comprising aplurality of supports to support the support surface, the plurality ofsupports being oriented to enable the at least one lifting member to beinserted into the at least one opening.
 6. The container as recited inclaim 5, wherein each of the plurality of supports comprises a hollowcylinder.
 7. The container as recited in claim 5, wherein each of theplurality of supports comprises a cellulosic material.
 8. A container ofwelding wire for an arc welding system, comprising: a hollow housinghaving at least one opening adapted to receive at least one liftingmember of a lifting device; and a length of welding wire disposed withinthe housing.
 9. The container as recited in claim 8, wherein the housingcomprises a fibrous material.
 10. The container as recited in claim 8,wherein the housing is generally cylindrical.
 11. The container asrecited in claim 8, comprising a first bottom and a second bottomadapted to support the welding wire.
 12. The container as recited inclaim 11, wherein both the first and the second bottoms comprise afibrous material.
 13. The container as recited in claim 11, comprisingat least one support disposed between the first bottom and the secondbottom.
 14. The container as recited in claim 13, wherein the at leastone support comprises a fibrous material.
 15. The container as recitedin claim 13, wherein the at least one opening is oriented on the housingbetween the first and second bottoms.
 16. The container as recited inclaim 8, wherein the lifting device is a forklift and the at least onelifting member is a fork of the forklift.
 17. A container of weldingwire for an arc welding system, comprising: a hollow housing; andwelding wire disposed within the housing, wherein the housing is adaptedto enable a lifting member of a lifting device to extend below thewelding wire to lift the housing.
 18. The container as recited in claim17, wherein the housing is generally cylindrical.
 19. The container asrecited in claim 17, wherein the housing comprises a cellulosicmaterial.
 20. The container as recited in claim 17, wherein the housingcomprises at least one opening in the housing to enable the liftingmember to enter the housing below the welding wire.
 21. The container asrecited in claim 17, wherein the housing comprises a bottom and a falsebottom disposed above the bottom, wherein the welding wire is disposedon the false bottom.
 22. The container as recited in claim 21, whereinthe housing comprises a plurality of supports disposed between thebottom and the false bottom and oriented.
 23. The container as recitedin claim 22, wherein the housing consists essentially of a singlerecyclable material.
 24. The container as recited in claim 17, whereinthe lifting member is a fork.
 25. A method of manufacturing a containerfor housing welding wire, comprising the act of: adapting a welding wirehousing comprising a cellulosic material with at least one of an openingand a recess in the welding wire housing to enable a lifting member toextend into the at least one of an opening and recess to lift thewelding wire housing.
 26. The method as recited in claim 25, whereinadapting comprises disposing a raised bottom in the welding wire housingto support the welding wire.
 27. The method as recited in claim 26,wherein adapting comprises providing the at least one of an opening anda recess in the welding wire housing below the raised bottom.
 28. Themethod as recited in claim 27, wherein adapting comprises disposing atleast one support in the welding wire housing below the raised bottom,the at least one support being oriented in the welding wire housing toenable the lifting member to enter the at least one of an opening and arecess.
 29. A method of operating a welding system, comprising the actsof: inserting a lifting device into an opening of a welding wire storagecontainer housing welding wire; lifting the welding wire storagecontainer with the lifting device; and operating the lifting device tomove the welding wire storage container to a desired location.
 30. Acontainer for storing a material, comprising: a housing comprising acellulosic material and having a raised support for disposing thematerial at an elevated location, wherein the housing is adapted toenable a lifting member to be disposed below the raised support to liftthe housing.
 31. The container as recited in claim 30, wherein thehousing is generally cylindrical.
 32. The container as recited in claim30, wherein the housing comprises at least one opening in the housing toenable the lifting member to enter the housing below the raised support.33. The container as recited in claim 32, wherein the at least oneopening is adapted to receive a fork of a forklift.
 34. A recyclablecontainer for welding wire, comprising: a welding wire housing adaptedto house welding wire and to be lifted by a lifting device, wherein thewelding wire housing consists essentially of a single material.
 35. Thecontainer as recited in claim 34, wherein the welding wire housingcomprises a support structure to house the welding wire at a raisedlocation within the welding wire housing.
 36. The container as recitedin claim 35, wherein the single material comprises a cellulosicmaterial.
 37. The container as recited in claim 34, comprising arestraint to secure the welding wire within the welding wire housingduring transport, wherein the restraint is removable and comprises asecond material.
 38. The container as recited in claim 34, comprising acover disposed on the welding wire housing.